For the Sake of the Environment and the Economy a New SCADA System Based on System 800Xa

For the sake of the environment and the economy A new SCADA system based on System 800xA

TVIS (Trekantområdets Varmetransmissions- selskab I/S) is a heat transmission company for the municipalities of Fredericia, Kolding, Middelfart, Børkop and Vejle. These municipalities forms the Trekantområdet geographical area of Denmark and has 55.000 households. TVIS is taking care of excess heat from the in- dustries and power plants in the area. The heat is then distributed in pipelines to house-holds, public institutions, offices, shops etc. in the municipalities. ABB in Denmark has supplied a SCADA solution based on System 800xA for controlling this district heating network. Five control rooms have received new operator systems based on System 800xA

The Danish tax policy helps to make district heating. Collecting, combining and exploiting ABB has supplied the new SCADA system based on heating good value for money, but even if this the excess heating from processes and using it System 800xA to the TVIS were not the case, district heating is a benefit for public heating purposes must, therefore, be district heating utility in Den- mark. The dispatch centre for the environment under all circumstances. in everyone’s interest. of TVIS is in Fredricia. The Trekantsområdet’s Varmetransmissionsselskab main supplier of heat is the Skærbæk combined cycle I/S (the ‘Triangle Area’ Heat Transmission The Danish tax policy, makes district heating a power plant. company, TVIS), receives industrial excess heat sensible investment and is also the background equivalent to the burning of 130,000,000 to the start-up and continued profitable opera- litres of diesel oil every year or a decrease in tion of TVIS, which was formed in 1983.

emissions equal to 225,000 tons of CO2. Industrial excess heat Imagine the scenario: a fire crackles pleas- Previously, the municipalities in the Trekant- antly in the small oil burner in each individual området geographical area of Denmark was home. An oil burner that is often old and supplied with heat from several sources that poorly maintained, and which therefore burns were not linked to one another. The munici- very inefficiently. The nearby power plant pality of Fredericia received excess heat from sends its cooling water for cooling into the what was then Superfos, a fertilizer industry, surrounding sea, resulting in a change to the and it was also possible to use the excess heat fauna and poor efficiency, while a refinery from Shell’s refinery and power plant heat pumps thousands of cubic metres of warm from the Skærbæk plant. So Vejle, Børkop, air and water out into the great outdoors. The Fredericia, Middelfart and Kolding invested a answer to these scenarios, which are, sadly, total of DKK 1.8 billion in setting up TVIS, and reality across most of the world, is district thus linking these municipalities for heating

2 purposes. They also included the stantly monitor and control the SCADA system at TVIS’ head heat from waste incineration in supply from the various suppliers office in Fredericia, where the 14 Kolding and Middelfart. These heat so that heat can always be supplied employees deal with everything to sources are supplemented with at the most advantageous price. do with documentation, operation local peak and reserve production and maintenance. The SRO system The heat is transferred via heat is based on a System 800xA solu- Purchase and sale exchangers to TVIS’ 75-kilometre tion delivered by ABB Denmark. In 1987, the district heating pipe main network of double pipes, In addition, each individual pump- was fully expanded, and since then which supply it on at a tempera- ing station is equipped with a PLC TVIS has fulfilled its role by pur- ture of up to 120 degrees Celsius controller from ABB, which in chasing the excess heat and selling and a pressure of up to 25 bar. turn is linked to the main SCADA it on at cost price to local district The pressure is reduced to 6 bar system in Fredericia. Each station heating companies. In 2006, TVIS and temperatures to 99 degrees or can also operate independently paid off the last of its debts and is lower for use in individual areas in the event of a fault elsewhere now ready for new challenges. of the network. in the system. The SCADA system logs all data and guarantees The heating supply comes, as Low heat loss overall automatic control and mentioned, from refuse burning in The diameter of the pipes starts supervision of the entire system, Kolding and Middelfart, as well as at 650 millimetres and falls, at as well as allowing the operator from Shell’s refinery – sources that the furthest end, to 150 millime- to intervene manually and control are always fully exploited. Heat is tres. Due to the excellent insula- the entire system, or parts of it. also supplied from the Skærbæk tion and the effective control of The SCADA system and control combined cycle power plant, which pumps, temperatures and flow, the principles are being constantly is slightly more expensive. During heat loss is only three per cent. developed and refined so that peak loads, extra boilers are con- 5 booster stations, 28 exchange TVIS’ system is now run optimally nected up, which, however, are stations and 19 valve and boiler with regard to reliability and even more expensive to run. stations – a total of 52 substations energy efficiency. It is therefore important to con- are linked together in a main

Shell’s refinery in Fredericia (above) supplies a reasonably constant quantity of excess heat, as do the waste burning plants in Kol- ding and Middelfart. Fluctuations in the load are dealt with by supplementing the heat from the Skærbæk plant with local peak and 22 stations are ready to deal with heat production during peak loads. Each station is equip- reserve production. ped and monitored by a PLC controller from ABB, which is linked in turn to the huge System 800xA based SCADA system in Fredericia.

3 75 kilometres of pipes District heating for the sake of room itself, and thus gain the option of a new TVIS purchases and resells heat the environment. The excess heat and improved overview of the remote heating from Shell’s refinery and the used by TVIS for district heating network. By guaranteeing operators access Skærbæk power plant. Heat from reduces the annual environmental to the right information and also improving waste burning is also included in impact by 225.000 tons of CO2, the physical working conditions with new, the area’s supply. The five muni- corresponding to chimney smoke ergonomic control room furniture, TVIS could cipalities supplied are themselves from the burning of 130,000,000 optimise operations and also make it more responsible for distribution to litres of diesel oil. attractive to be on operations duty. individual households. 75 kilometres of double pipes transport The TVIS project has focused the 30,000 cubic metres of water attention on the development of in the system. The system runs at Danish district heating systems in a pressure of up to 25 bar and a a socio-economic and environ- supply of up to 120 degrees mentally-correct direction. And it Celsius, which changes to 6 bar has provided ideas for solutions to and a supply of up to 99 degrees global environmental problems. in the municipalities’ own net- TVIS have always placed a high works. There are five booster priority on having overview and pumping stations with a total of the working conditions for its A schematic display of TVIS’ heat production in 2006 20 pumps in the system, and the operators, so when they decided where blue is from waste-to-energy plant, yellow from total system delivers 350-400 MW Shell, green from Skærbæk, purple from Carlsberg to upgrade the existing SCADA Tuborg and red from peak load stations. Heat from Carls- of district heating from the 28 heat system to System 800xA, they also berg Tuborg brewery can only be used in a few periods. exchanger stations. For example in June when Shelll´s refinery (yellow) was decided to modernise the control closed for maintenance it was also necessaary to use the more expensive in-house production (red). Delivery reliability TVIS supplies heat to 50,000 hous- System 800xA System 800xA eholds. Over more than 20 years, Workplace I Workplace II Workplace PC’er they have pumped hot water to WP3 WP2 WP1 citizens in Kolding, Fredericia, Børkop, Middelfart and Vejle. SCADA TCP/IP net During the same period, ABB has 1 2 serviced the controls for the nume- SQL1 CTX1 DC1 DC2 AS1 AS2 CS1 CS2 ISDN Printer rous pumps, and together with Router

TVIS’ operations department repla- Router Office PC connection Office PC SQL- Terminal- Domain Aspect Connectivity Office PC ced and modernised the automatic server server Controllers Servers Servers Office PC ISDN system at a sensible pace. IP port server

Recently, an ultra-modern control R R R R R R R R R R R R R Radio R room with a curved giant screen R R connections, R R R R R R R R Adm. TCP/IP net R R R RCOM R R R has been established, providing R R R R R R R R R R R R operations engineers with a per- R R R UST R R R R R R R R AC110 R R R R fect overview. R R AC55 R The System 800xA configuration layout of the SCADA solution for TVIS.

4 New control room furniture as it was to look once it operation, and show them on the Via the SCADA system, the seven was finished. The control system giant screen. Here they can also operators and their managers contains something very special, change all the specified param- control the operations based on namely a curved, height-adjustable eters for operation, so supply information from thousands of desk with a total of seven LCD reliability and economics go hand measurement points out in the screens placed in front of a curved in hand, ensuring consumers network. At the same time, they giant screen close to the opera- receive the best possible deliv- deal with maintenance and replace tors and operated by three projec- ery. The solution to the control parts as they become worn or old. tors. This new operator console room is based on System 800xA However, always so that all the or Extended Operator Workplace with three operator workplaces of stations function the same. (EOW) provides perfect overview which one is for the large curved The old control room was in images of the entire process with screen. PLC Connect are utilized need of replacement, and ABB, excellent graphics. This solution to communicate with all ABB PLC which had previously supplied gives hence a first class working controllers in the pump stations most of the control solutions, environment for the operators (AC 110 and AC 55). was selected as the supplier. The meeting highest ergonomical recently equipped control room standards. On the LCD screens, is in a class of its own. Initially, the operators can obtain the 200 it was designed by the company or so process displays specifying CGM, Sweden as a 3D file with flow, pressure, temperatures and giant screen and control room other important parameters for

The improved modern control tech- nology thanks to the System 800xA solution plus furnishings, including a giant screen, where the images of the different sites can be viewed and serviced, meets the approval of the operations engineers. Morten Thomsen (right) and Johnny Borgen enjoy the advantages of the new operator environment.

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